Slip-resistant floor coverings

ABSTRACT

The invention provides a synthetic slip-resistant floor-covering material comprising a layer of synthetic material which contains one or more degradable polymeric particles wherein the one or more degradable polymeric particles comprise: (a) one or more hard degradable polymeric particles which have a hardness which is greater than the hardness of the layer of synthetic material; and optionally (b) one or more soft degradable polymeric particles which have a hardness which is the same as or less than the hardness of the layer of synthetic material; and wherein the one or more hard degradable polymeric particles comprise one or more exposed hard degradable polymeric particles which are exposed at an upper surface of the synthetic floor-covering material to provide slip-resistance; and a method of preparing a synthetic floor-covering which method comprises the steps of: Providing a layer of synthetic material; Applying the one or more degradable polymeric particles to the layer of synthetic material; and Applying pressure to the layer of synthetic material to ensure that the one or more degradable polymeric particles are incorporated into the layer of synthetic material.

The present invention relates to an improved slip-resistantfloor-covering particularly in the form of a luxury vinyl tile and amethod for its production.

Slip resistant floors typically use one or more of the followingmechanisms to achieve slip resistance:

-   -   a. Inorganic particles (e.g. silicon carbide, aluminium oxide)        embedded in the wear layer, protruding to a sufficient extent to        provide slip resistance;    -   b. A texture which is embossed into the wear layer; and/or    -   c. A surface coating on the wear layer, containing particles        (e.g. glass, aluminium oxide, polymeric) which provide slip        resistance

The inorganic particles have the advantage of being less susceptible tomechanical wear, and therefore provide sustained slip resistancethroughout the lifetime of the product (e.g. 20 years). However, theyhave the disadvantage that they can disrupt the design of the product(e.g. a printed design). Additionally, the inorganic particles causerapid wear on cutting equipment and any particles present at a cut edgewill produce a rough edge (see edges C32 and D32 for the first andsecond comparative embodiments C30 and D30 illustrated in FIGS. 7 and 8, respectively), either by protruding (illustrated by protrudingparticle 68 in FIG. 8 ) or by becoming dislodged and leaving a void(illustrated by partial particle void 66 in FIG. 7 ). In addition toaesthetic issues, this rough edge can trap dirt and make the productdifficult to clean. These difficulties are especially pronounced if theproduct is cut into tiles, such as in the production of a Luxury VinylTile (LVT).

A way of ameliorating these problems has been sought.

According to the invention there is provided a synthetic slip-resistantfloor-covering material comprising a layer of synthetic material whichcontains one or more degradable polymeric particles wherein the one ormore degradable polymeric particles comprise:

-   -   (a) one or more hard degradable polymeric particles which have a        hardness which is greater than the hardness of the layer of        synthetic material; and optionally    -   (b) one or more soft degradable polymeric particles which have a        hardness which is the same as or less than the hardness of the        layer of synthetic material; and

wherein the one or more hard degradable polymeric particles comprise oneor more exposed hard degradable polymeric particles which are exposed atan upper surface of the synthetic floor-covering material to provideslip-resistance.

According to the invention there is further provided a method ofpreparing a synthetic floor-covering which method comprises the stepsof:

-   -   Providing a layer of synthetic material;    -   Applying the one or more degradable polymeric particles to the        layer of synthetic material; and    -   Applying pressure to the layer of synthetic material to ensure        that the one or more degradable polymeric particles are        incorporated into the layer of synthetic material.

Advantages of the invention include that:

-   -   a. When the product is cut the polymeric particles will also be        cut, giving an edge which does not present the problems        mentioned previously.    -   b. Any polymeric particles which are dislodged from the        floor-covering material should not present a microplastics        problem as they are degradable. Currently known microplastics        problems include marine pollution and plastics entering the food        chain.

In some embodiments, the slip-resistant floor-covering material has asurface emboss and/or a layer of slip-resistant particles which arepartially embedded in an upper surface of the floor-covering material.

In some embodiments, the degradable polymeric particles may bedecomposable without burning or combustion to avoid risk of airpollution. In some embodiments, the degradable polymeric particles maybe biodegradable (for example by micro-organisms such as bacteria and/orfungi), oxidatively degradable, UV-degradable, and/or thermallydegradable. In some embodiments, a biodegradable polymeric particle maybe biodegradable in a bioreactor landfill (as determined by ASTMD5511-12 standard test method), an accelerated landfill (as determinedby ASTM D5526-12 standard test method), controlled composting conditions(as determined by ASTM D5338-98e1 standard test method), and/or aerobiccomposting conditions (as determined by ASTM D6400-12 and/or EN13432(September 2000)). It should be understood herein that a biodegradablepolymeric particle that satisfies ASTM D5511-12 is suitable foranaerobic biodegradation under high-solids anaerobic-digestionconditions; a biodegradable polymeric particle that satisfies ASTMD5526-12 is suitable for anaerobic biodegradation under an acceleratedlandfill environment where leachate is recirculated back into thelandfill; a biodegradable polymeric particle that satisfies ASTMD5338-98e1 is suitable for aerobic biodegradation in an aerobicenvironment at 60° C.; a biodegradable polymeric particle that satisfiesASTM D6400-12 is suitable for aerobic composting in municipal orindustrial facilities within 180 days at a temperature between 55.5° C.and 57° C.

In some embodiments, the one or more polymeric degradable particles maybe formed from a polymer which may be pigmented or substantiallytransparent. In some embodiments, the one or more degradable polymericparticles may be formed from a polymer which has a melting point greaterthan 120° C. (e.g. greater than 130° C. or greater than 140° C.) suchthat it retains its shape during the formation of the layer of syntheticmaterial. Typically, such formation may include gelling (e.g. on agelling drum or in an oven). In an alternative embodiment, the layer ofsynthetic material comprising the one or more degradable polymericparticles may be formed by laminating such that the melting point of thepolymer may be less. In some embodiments, the one or more degradablepolymeric particles may be formed from a polyhydroxyalkanoate (e.g. PHAand/or PHB), acrylic copolymer, nylon, and/or a polyester (such aspolyglycolic acid, a terephthalate copolymer (such as polyethyleneterephthalate and/or polybutylene terephthalate), polycarbonate orpolycarbonate copolymer, and/or polylactic acid). In some embodiments,the one or more degradable polymeric particles may comprise one or moredifferent types of different degradable polymeric particles.

In some embodiments, the one or more degradable polymeric particles maybe transparent or partially opaque that are not so opaque that theyobscure the appearance of any underlying decorative layer. Advantages ofusing polymeric particles with such a refractive index include that theyare substantially transparent, and so would not disrupt the appearanceof any printed design layer in the floor-covering material.

In some embodiments, the one or more degradable polymeric particles mayhave a principal dimension (such as a diameter) of from 15%, e.g. from20%, e.g. from 25% to 90%, e.g. to 80%, e.g. to 70%, e.g. to 60%, e.g.to 50% of the thickness of the layer of synthetic material.

In some embodiments, the floor-covering material may have a surfaceemboss to provide a non-slip surface. In some embodiments, the surfaceemboss may have a maximum depth of from 5 μm, e.g. from 10 μm to 200 μm,e.g. to 150 μm, e.g. to 100 μm.

In some embodiments, the one or more degradable polymeric particles mayhave a hardness which is the same as or different to a hardness of thelayer of synthetic material. In some embodiments, the one or moredegradable polymeric particles may comprise one or more hard degradablepolymeric particles suitable for use as non-slip particles. In someembodiments, the layer of synthetic material which contains the one ormore hard degradable polymeric particles may form an upper layer of thefloor-covering covering material or may be exposed as an upper layer ofthe floor-covering covering material during use. In some embodiments,the one or more hard degradable polymeric particles may have a hardnesswhich is greater than a hardness of a layer of synthetic material inwhich the hard degradable polymeric particles are placed such that thehard degradable polymeric particles are exposed through wearing of thelayer of synthetic material. In some embodiments, the one or more harddegradable polymeric particles may be formed from a polyester (forexample polylactic acid and/or polyglycolic acid, a terephthalatecopolymer (such as polyethylene terephthalate and/or polybutyleneterephthalate), polycarbonate or polycarbonate copolymer) and/or nylon.

It is not straightforward to quantify the difference in hardness betweenthe one or more degradable polymeric particles and the layer ofsynthetic material because different measurement scales can be used forthermoplastic polymers. Typically, the Shore D hardness scale is usedfor relatively soft thermoplastic polymers and the Rockwell M hardnessscale is used for relatively hard thermoplastic polymers. In someembodiments, the hard polymeric degradable particles may have a hardnesswhich is only quantifiable on the Rockwell M hardness scale and thesynthetic material may have a hardness which is only quantifiable on theShore D hardness scale. In some embodiments, where the hard degradablepolymeric particles have a hardness which is quantifiable on the Shore Dhardness scale, the hard polymeric degradable particles may have ahardness which is from 2-10 Shore D at 23° C. harder than the Shore D at23° C. hardness value for the layer of synthetic material, for exampleabout 5 Shore D at 23° C. greater than the Shore D at 23° C. hardnessvalue for the layer of synthetic material. Shore D Hardness is astandardized test consisting in measuring the depth of penetration of aspecific indenter. Test methods used to measure Shore D Hardness areASTM D2240 and ISO 868. The hardness value is determined by thepenetration of a Durometer indenter foot into a sample. Shore Hardnessmeasures are dimensionless and may vary from 0 and 100 where a highernumber represents a harder material. In some embodiments, the hardnessof the hard degradable polymeric particles and of the layer of syntheticmaterial are measured according to ASTM D2240 type D scale at 23° C.(+/−2° C.) and at 50% relative humidity (+/−5%). In some embodiments,the hardness of the hard degradable polymeric particles is measured onthe Rockwell hardness M-scale according to ISO2039-2. Advantages ofincluding one or more hard degradable polymeric particles in an upperlayer of the floor-covering covering material or is exposed as an upperlayer of the floor-covering covering material during use include thatthe hard degradable polymeric particles are fully embedded in the wearlayer and do not affect the maintenance of the product. Only insituations where high product wear is experienced will these particlesbe exposed through wearing of the layer of synthetic material.Furthermore, the difference in wear resistance between the harddegradable polymeric particles and the wear layer will cause the harddegradable polymeric particles to become exposed, creating surfaceroughness which produces slip resistance.

In some embodiments, the floor-covering material may have a layer of oneor more hard degradable polymeric particles which are partially embeddedin an upper surface of the floor-covering material. In some embodiments,the floor-covering material may have a layer of one or more harddegradable polymeric particles which are entirely embedded in a layer ofsynthetic material.

In some embodiments, the one or more degradable polymeric particles maycomprise one or more soft degradable polymeric particles suitable foruse as decorative particles. In some embodiments, the one or more softdegradable polymeric particles may have a hardness which is less thanthe hardness of the layer of synthetic material such that the polymericparticles wear with the layer of synthetic material. In someembodiments, the one or more soft degradable polymeric particles may beformed from polyhydroxyalkanoate (e.g. PHA and/or PHB) and/or an acryliccopolymer. In some embodiments, the soft polymeric degradable particlesmay have a hardness which is from 2-10 Shore D at 23° C. softer than theShore D at 23° C. hardness value for the layer of synthetic material,for example about 5 Shore D at 23° C. less than the Shore D at 23° C.hardness value for the layer of synthetic material. In some embodiments,the hardness of the soft degradable polymeric particles and of the layerof synthetic material are measured according to ASTM D2240 type D scaleat 23° C. (+/−2° C.) and at 50% relative humidity (+/−5%).

In some embodiments, the floor-covering material may have a layer of oneor more soft degradable polymeric particles are entirely embedded in alayer of synthetic material. In some embodiments, the floor-coveringmaterial may have one or more soft degradable polymeric particles whichmay comprise one or more decorative soft degradable polymeric particles.

In some embodiments, the degradable polymeric particles may be formedfrom polylactic acid (typical Shore D value of about 59 to 77 at 23°C.). In some embodiments, the degradable polymeric particles may beformed from polyglycolic acid (typical Rockwell hardness M-scale ofabout 105 to 115). In some embodiments, the degradable polymericparticles may be formed from polyacrylic acid (typical Rockwell hardnessM-scale of about 70 to 105). In some embodiments, the degradablepolymeric particle may be formed from polyethylene terephthalate(typical Shore D value of about 85 to 95 at 23° C.). In someembodiments, the degradable polymeric particle may be formed frompolybutylene terephthalate (typical Shore D value of about 90 to 95 at23° C.). In some embodiments, the degradable polymeric particle may beformed from polycarbonate (typical Shore D value of about 90 to 95 at23° C.).

In some embodiments, the floor-covering material may comprise aprotective coating layer on the layer of synthetic material to form anupper layer of the floor-covering material. In some embodiments, theprotective coating layer may comprise a non-slip layer. In someembodiments, the non-slip layer may comprise one or more non-slipparticles suitable for providing a non-slip surface wherein suchnon-slip particles are at least partially embedded in the protectivecoating layer. In some embodiments, the non-slip particles may compriseone or more hard degradable polymeric particles, one or more inorganicparticles (such as aluminium oxide, silicon carbide, quartz and/orglass) and/or one or more organic particles (such as nylon, acrylic,and/or polyurea). In some embodiments, the non-slip particles may have aprinciple dimension (such as a diameter) of from 3, e.g. from 5, e.g.from 10 to 150 μm, e.g. to 130 μm, e.g. to 110 μm, e.g. to 90 μm. Theinitial slip resistance will be provided by the surface coating, andoptionally by the surface emboss. These can be designed to provide slipresistance and ease of maintenance without detracting from theappearance of the product

In some embodiments, the layer of synthetic material may be formed froma plasticised PVC, polyolefin, polyurethane, an ionomer (such as DupontSurlyn), EVA, and/or any other flexible polymer. In some embodiments,the layer of synthetic material may be pigmented or may be substantiallytransparent. Typically, polyvinyl chloride plasticized by about 40 phrof plasticiser has a Shore D value of about 35 to 40 at 23° C., ethylenevinyl acetate has a Shore D value of about 15-45 at 23° C., a polyolefinsuch as polyethylene has a Shore D value of about 40 to 56 at 23° C.(depending upon the type used), a polyurethane has a Shore D value ofabout 45 to 60 at 23° C. (depending upon the type used). In someembodiments, the degradable polymeric particles may have a Shore Dhardness of from 20, e.g. from 40, e.g. from 45, e.g. to 95, e.g. to 90,e.g. to 85, e.g. to 80, e.g. to 75, e.g. to 70, e.g. to 65 at 23° C.

In some embodiments, the layer of synthetic material and the one or moredegradable polymeric particles may be pigmented. In some embodiments,the pigment of the one or more degradable polymeric particles may be thesame as that for the layer of synthetic material or may have a different(such as a contrasting) colour.

In some embodiments, the floor-covering material may be a sheet materialor a luxury vinyl tile. In some embodiments, floor-covering sheetmaterial may be provided in the form of a roll. In some embodiments, aluxury vinyl tile may comprise a decorative layer and wherein the layerof synthetic material is provided on an upper surface of the decorativelayer and wherein the layer of synthetic material is substantiallytransparent. In some embodiments, the floor-covering material maycomprise a lower foamed layer. In some embodiments, the foam layer mayinclude a plurality of layers of synthetic material of which one or moremay be foamed to provide comfort to a user. In some embodiments, thefloor-covering material may have a substantially smooth cut edge. Insome embodiments, the substantially smooth cut edge may be vertical orbevelled such that it is at an angle.

In some embodiments, the layer of synthetic material may include one ormore partial polymeric degradable particles. In some embodiments, apartial polymeric degradable particle may be formed by cutting thefloor-covering material.

In some embodiments, the layer of synthetic material may have athickness of from 0.2 mm, e.g. from 0.3 mm, e.g. from 0.5 mm to 2 mm,e.g. to 1.8 mm, e.g. to 1.6 mm, e.g. to 1.4 mm, e.g. to 1.2 mm, e.g. to1 mm.

In some embodiments, the protective coating layer may comprise a curedpolymer layer; suitable polymers for use in the protective coating layerinclude polyurethane, polyacrylate, urethane acrylate and/or a PVDFbased composition. In some embodiments, the protective coating layer mayhave a thickness of from 5 to 50 μm. In some embodiments, a suitablecoating composition for forming a protective coating layer may be a UVcurable mixture containing an oligomeric acrylic (which acts as abinder), one or more monomeric acrylics (which acts as a solvent) and aphotoinitiator, where each component is cross-linked.

In some embodiments, the synthetic floor-covering material may beprovided in the form of a roll or one or more tiles.

In some embodiments, the floor-covering material may be formed from oneor more synthetic materials such as a plastics material such as apolymeric material. Suitable plastics materials include PVC, polyvinylbutyral (PVB), polylactic acid (PLA), polyester, a polyolefin, athermoplastic elastomer and/or polyacrylate.

In some embodiments, the floor-covering material may include one or moreof the following layers: a foamed layer, a support layer, a decorativelayer, a topcoat layer, a clear wear layer, and/or an externalprotective coating layer. In some embodiments, the method step ofproviding a layer of synthetic material may comprise providing one ormore of the following layers: a foamed layer, a support layer, adecorative layer, a topcoat layer, a clear wear layer. In someembodiments, the method may comprise the step of: applying a protectivecoating layer wherein this step is carried out after the step ofapplying pressure to the layer of synthetic material.

In some embodiments, the floor-covering material may include a supportlayer. In some embodiments, the support layer may be provided on a lowersurface of the layer of synthetic material or on a lower surface of thedecorative layer. In some embodiments, the support layer may be anoptionally woven layer. In some embodiments, the support layer may beformed from fibres (such as glass fibres, synthetic fibres, or a mix).In some embodiments, the support layer may be a scrim complex. In someembodiments, the support layer may have an impregnated layer of plasticsmaterial.

In some embodiments, the floor-covering material may include adecorative layer which may be provided on an upper surface of thesupport layer (if present). In some embodiments, the decorative layermay comprise a printing layer and a printed design layer.

In some embodiments, the printing layer may be suitable for receiving aprinted design or having a printed design applied to it by a digital orgravure printer. In some embodiments, the printing layer may have apigment which is suitable for providing a background to a printed designwhere such a pigment may have a similar or contrasting colour to one ormore colours in the printed design, e.g. a white pigment. In someembodiments, the printing layer may be formed from a plastics materialwhich may comprise, for example, one or more of the following polymers:PVC, polyvinyl butyral (PVB), polylactic acid (PLA), polyester, apolyolefin, a thermoplastic elastomer and/or polyacrylate.

In some embodiments, the printed design layer may comprise a decorationapplied by a printing process, for example offset lithography,flexography, digital printing, gravure, or screen printing. In someembodiments, the printed design layer may be a digitally printed designlayer. In some embodiments, the printed design layer may comprise alatex-based ink.

In some embodiments, the decorative layer may be a layer having adecoration such as a pattern. In some embodiments, a decoration orpattern may comprise one or more decorative elements such as adecorative or coloured chip or particle which may be formed from anoptionally coloured polymeric or inorganic material.

In some embodiments, the floor-covering material may include a topcoatlayer. A topcoat layer may be used as an alternative to a decorativelayer. In some embodiments, the topcoat layer may be pigmented. Benefitsof including a pigmented topcoat layer include that where thefloor-covering material includes a support layer, the pigmented topcoatlayer prevents the support layer from being seen. In some embodiments,the topcoat layer may include one or more decorative elements. In someembodiments, the one or more decorative elements may be formed from oneor more soft degradable polymeric particles, glass, a ceramic material,an inorganic material (such as aluminium oxide or silicon carbide),and/or a plastics material (such as PVC, polyvinyl butyral (PVB),polylactic acid (PLA), polyester, a polyolefin, a thermoplasticelastomer and/or polyacrylate). In some embodiments, each of the one ormore decorative elements may be in the form of a chip having a visibleflat surface, a bead or a sphere.

In some embodiments, the foamed layer may comprise a foamed plasticsmaterial capable of imparting a sound attenuation effect, for example anacoustic impact sound reduction of more than 10 dB. In some embodiments,the acoustic impact sound absorption may be from 4 dB, e.g. from 6 dB,e.g. from 8 dB, 10 dB, e.g. from 12 dB to 22 dB, e.g. to 20 dB, e.g. to18 dB, e.g. to 16 dB. In some embodiments, the acoustic impact soundabsorption may be 12 dB, 14 dB, 16 dB, or 18 dB. In some embodiments,the foamed plastics material may be mechanically foamed by incorporatingone or more types of compressible plastic spheres. In some embodiments,the foamed plastics material may be chemically foamed by an exothermicor endothermic blowing agent. In some embodiments, the blowing agent maybe an azodicarbonamide, modified azodicarbonamide,oxy-bis(benzene-suldonylhydrazide), 5-phenyltetrazole,p-Toluylensulfonyl-semicarbazid or p-Toluylensulfonyl-hycarbazide; forexample, the blowing agent may be Hydrocerol® (Clariant) or Toamazol™(Bergen International). In some embodiments, the foamed layer maycomprise one or more of the following polymers: PVC, polyvinyl butyral(PVB), polylactic acid (PLA), polyester and/or polyacrylate.

In some embodiments, the floor-covering material may be embossed toprovide a decorative finish and/or to improve the non-slip properties ofthe floor-covering material. In some embodiments, the non-slip layercomprises one or more particles suitable for providing a non-slipsurface. In some embodiments, the particles may be at least partiallyembedded in the floor-covering material. In some embodiments, theparticles may comprise one or more aggregate materials. In someembodiments, the particles may comprise one or more types of slipresistant particles such as a glass particle (e.g. a recycled glassbead), a silica particle, a silicon carbide particle, a polymericparticle (for example Nylon (Trademark)), a ceramic particle (e.g.porcelain) and/or an aluminium oxide particle. In some embodiments, theparticles may be spherical, semi round, cubical, amorphous, shard shapeor have a flake-like construction. In some embodiments, the particlesmay be smooth particles. A smooth particle is a particle which has noangular protrusion or indentation, for example a particle which has noprotrusion or indentation having an outward facing angle of about 90° orless. In some embodiments, the particles may be one or more of a smoothsphere, bead, and/or grain. The advantage of using a smooth particle inthe floor-covering material according to the invention is that the curedcoating is easier to clean as the coating lacks any angular surface inwhich a cleaning material (for example the fibres of a mop) may becaught.

The invention will now be described with reference to the followingFigures of the accompanying drawings which are not intended to limit thescope of the invention in which:

FIG. 1 shows a schematic cross-section of a first embodiment of afloor-covering material according to the invention;

FIG. 2 shows a schematic cross-section of a second embodiment of afloor-covering material according to the invention;

FIG. 3 shows a schematic cross-section of a third embodiment of afloor-covering material according to the invention;

FIG. 4 shows a schematic cross-section of a fourth embodiment of afloor-covering material according to the invention

FIG. 5 shows a schematic cross-section of a fifth embodiment of afloor-covering material according to the invention in the form of aluxury vinyl tile;

FIG. 6 shows a schematic cross-section of a sixth embodiment of afloor-covering material according to the invention in the form of atile;

FIG. 7 shows a schematic cross-section of a first comparative embodimentof a floor-covering material which is not according to the inventionwherein the first comparative embodiment is in the form of a luxuryvinyl tile; and

FIG. 8 shows a schematic cross-section of a second comparativeembodiment of a floor-covering material which is not according to theinvention wherein the second comparative embodiment is in the form of atile.

The first embodiment of a floor-covering material according to theinvention is indicated generally at 30 on FIG. 1 . Floor-coveringmaterial 30 comprises a lower layer 32 in the form of a foam-formingplastics material comprising a plasticised PVC composition and anazodicarbonamide, a support layer 33 in the form of a non-woven glassfibre layer arranged on an upper surface of the lower layer 32, animpregnation layer 35 formed of plastics material arranged on an uppersurface of the support layer 33, a pigmented printing layer 37 (formedfrom a pigmented plasticised PVC composition having a white pigment) onan upper surface of the impregnation layer 35, a printed decorativelayer 34 on an upper surface of the pigmented printing layer 37, a layerof synthetic material in the form of clear wear layer 36 on an uppersurface of the decorative layer 34, and a polyacrylate protectivecoating layer 38 on an upper surface of the clear wear layer 34. Theclear wear layer 36 includes a transparent polymeric particle layer 50formed from one or more exposed hard transparent degradable polymericparticles 52A which are partially embedded in the wear layer 36 and oneor more embedded hard transparent degradable polymeric particles 52Bwhich are entirely embedded in the wear layer 36. Thus, some of the hardtransparent degradable polymeric particles 52A,B of the layer ofdegradable polymeric particles 50 is exposed at the surface of thefloor-covering material 30 to provide a non-slip effect. The one or moredegradable polymeric particles 52A,B are referred to as being hard asthey have a wear resistance which is substantially greater than that ofthe wear layer 36.

In an alternative embodiment, the lower layer 32 may be mechanicallyfoamed e.g. by incorporation of one or more compressible plasticspheres. In a further alternative embodiment, the hard degradableparticles 52A,B may be partially opaque.

The wear layer 36 may be formed from plasticised PVC, polyolefin,polyurethane, ionomers (such as Dupont Surlyn), EVA, or any otherflexible polymer that is substantially transparent. The wear layer mayhave a thickness of from 0.3 mm to 1 mm. The one or more degradablepolymeric particles 52A,B may be formed from a polymer which istransparent, is harder than the wear layer, and which has a meltingpoint greater than 140° C. such that it retains its shape during theformation and embossing of the wear layer 36.

Suitable materials for forming the one or more hard degradable polymericparticles 52A,B include a polyester (such as polyglycolic acid, aterephthalate copolymer, a polycarbonate and/or polylactic acid) ornylon. The one or more degradable polymeric particles 52 may be selectedto have a principal dimension (such as a diameter) of from 25% to 90% ofthe thickness of the wear layer 36. The floor-covering material 30 isembossed with a surface emboss (not shown) to provide the floor-coveringmaterial 30 with a non-slip surface. The surface emboss has a maximumdepth of from 10 to 500 μm. The protective coating layer 38 comprises acured polymer layer and has a thickness of from 5 to 50 μm.

The printed decorative layer 34 may be applied by any known suitableprinting technique such as digital printing or gravure printing on thepigmented printing layer 37. The pigmented printing layer 37 isformulated to be suitable for receiving the printed decorative layer 34.In an alternative embodiment, the pigmented printing layer 37 may bepigmented with a pigment having a colour other than white such as acolour which contrasts or complements the printed decorative layer 34.

Suitable polymers for use in the protective coating layer 38 includepolyurethane, polyacrylate, urethane acrylate or a PVDF basedcomposition. A suitable coating composition for forming protectivecoating layer 38 is a UV curable mixture containing an oligomericacrylic (the binder), monomeric acrylics (the solvent) and aphotoinitiator, where each component is cross-linked.

In an alternative embodiment, the lower layer 32 may be formed from anun-foamed plasticised PVC composition such that lower layer 32 is acompact lower layer 32. In a further alternative embodiment, the one ormore transparent degradable polymeric particles 52A,B may be entirelyembedded in the wear layer 36 such that they are not exposed at thesurface of the floor-covering material 30. As a result of the one ormore degradable polymeric particles 52A,B being entirely embedded in thewear layer 36, the maintenance of the floor-covering material 30 is notaffected by the one or more degradable polymeric particles 52A,B.

The second embodiment of a floor-covering material according to theinvention is indicated generally at 130 on FIG. 2 . Like features of thesecond embodiment to the first embodiment of the floor-covering materialare identified by like reference numerals. Floor-covering material 130comprises the layers of a floor-covering material 30 according to thefirst embodiment which are the lower layer 32 in the form of a foamedPVC layer, a support layer 33, an impregnation layer 35, a pigmentedprinting layer 37, a printed decorative layer 34, a layer of syntheticmaterial in the form of wear layer 36 incorporating an embedded particlelayer 50B of one or more embedded hard transparent degradable polymericparticles 52B, and a protective coating layer 38. In addition, theprotective coating layer 38 comprises a non-slip layer 40. The clearwear layer 36 includes a transparent polymeric particle layer 50 formedfrom one or more hard transparent degradable polymeric particles 52Bwhich are entirely embedded in the wear layer 36.

Non-slip layer 40 comprises one or more exposed hard transparentdegradable polymeric particles 42A and one or more non-slip particles42D suitable for providing a non-slip surface wherein such non-slipparticles 42A,D are at least partially embedded in the protectivecoating layer 38 and the wear layer 36. The non-slip particles 42D maycomprise one or more inorganic particles (such as aluminium oxide,silicon carbide, quartz and/or glass) and/or one or more organicparticles (such as nylon, acrylic, and/or polyurea). The non-slipparticles 42A,D may have a principal dimension (such as a diameter) offrom 5 to 110 μm. The floor-covering material 130 is suitable for use asa covering material for a floor as the non-slip surface is intended toreduce the risk of a person slipping when walking on the floor-coveringmaterial. In an alternative embodiment, the non-slip layer 40 of theprotective coating layer 38 may only comprise one or more exposed hardtransparent degradable polymeric particles 52A.

In situations where high product wear is experienced, the one or moreembedded hard degradable polymeric particles 52B will be exposed due tothe difference in wear resistance between the one or more embedded harddegradable polymeric particles 52B and the wear layer 36. Exposure ofthe one or more embedded hard degradable polymeric particles 52B willcreate surface roughness which produces slip resistance.

In an alternative embodiment, the one or more exposed hard transparentdegradable polymeric particles 42A and non-slip particles 42D may bepartially embedded only in the protective coating layer 38. In a furtheralternative embodiment, the embedded particle layer 50B may be aparticle layer 50 which comprises in addition to the one or moreembedded hard transparent degradable polymeric particles 52B, one ormore exposed hard transparent degradable polymeric particles 52A whichare partially embedded in the wear layer 36 such that they are exposedat the surface of the floor-covering material 130.

The third embodiment of a floor-covering material according to theinvention is indicated generally at 230 on FIG. 3 . Like features of thethird embodiment to the second embodiment of the floor-covering materialare identified by like reference numerals. Floor-covering material 230comprises the layers of a floor-covering material 130 according to thesecond embodiment which are the lower layer 32 in the form of a foamedPVC layer, a support layer 33, an impregnation layer 35, a pigmentedprinting layer 37, a printed decorative layer 34, a layer of syntheticmaterial in the form of wear layer 36 incorporating the embeddedparticle layer 50B, and a protective coating layer 38 where theprotective coating layer 38 comprises a non-slip layer 40. In addition,a fabric backing layer 31 is provided on the lower surface of the lowerlayer 32. Fabric backing layer 31 is in the form of a fleece layerhaving an exposed nap suitable for providing sound and/or heatinsulation to the floor-covering material 230. The floor-coveringmaterial 230 is suitable for use as a covering material for a floor.

The fourth embodiment of a floor-covering material according to theinvention is indicated generally at 330 on FIG. 4 . Like features of thefourth embodiment to the first, second, and third embodiments of thefloor-covering material are identified by like reference numerals.Floor-covering material 330 is a simpler surface-covering which does notinclude an impregnation layer 35, a pigmented printing layer 37 and aprinted decorative layer 34. Instead a pigmented topcoat layer 236 isprovided directly on the support layer 33. Floor-covering material 230comprises a lower layer 232 of synthetic material, a support layer 33 inthe form of a scrim complex arranged on an upper surface of the lowerlayer 232, a layer of synthetic material in the form of pigmentedtopcoat layer 236 on an upper surface of the support layer 33, apolyacrylate protective coating layer 38 incorporating the non-sliplayer 40 on an upper surface of the pigmented topcoat layer 236. Thesurface-covering 230 incorporates an embedded pigmented particle layer150B in pigmented topcoat layer 236. The pigmented particle layer 150includes pigmented hard embedded degradable polymeric particles 152B andpigmented soft embedded degradable polymeric particles 152C. The pigmentof the one or more hard embedded degradable polymeric particles 152B andpigmented soft decorative embedded degradable polymeric particles 152Cmay be the same colour as the pigment for the pigmented topcoat layer236 or may have a different pigment with a different (such as acontrasting) colour. The pigment of the one or more hard embeddeddegradable polymeric particles 152B and of the pigmented soft embeddeddegradable polymeric particles 152C may be the same or different. Thelower layer 232 is a compact lower layer 232 as it is not foamed. Thepigmented soft embedded degradable polymeric particles 152C may have ahardness which is the same as or less than the hardness of the pigmentedtopcoat layer 236. The pigmented soft embedded degradable polymericparticles 152C may be formed from a polyhydroxyalkanoate (e.g. PHAand/or PHB) and/or an acrylic copolymer.

In an alternative embodiment, the embedded particle layer 50B may be aparticle layer 50 which in addition to the one or more embedded hardtransparent degradable polymeric particles 52B, comprises one or moreexposed hard transparent degradable polymeric particles 52A which arepartially embedded in the wear layer 36 such that they are exposed atthe surface of the floor-covering material 130.

The fifth embodiment of a floor-covering material according to theinvention is indicated generally at 430 on FIG. 5 . Like features of thefourth embodiment 430 to the second embodiment of the floor-coveringmaterial 130 are identified by like reference numerals. Floor-coveringmaterial 430 is in the form of a luxury vinyl tile and has been cut fromthe floor-covering material 130 according to the second embodiment ofthe invention along the vertical line A-A′ indicated on FIG. 2 .Floor-covering material 430 comprises the layers of a floor-coveringmaterial 130 according to the second embodiment which are the lowerlayer 32 in the form of a foamed PVC layer, a support layer 33, animpregnation layer 35, a pigmented printing layer 37, a printeddecorative layer 34, a layer of synthetic material in the form of wearlayer 36, and a protective coating layer 38 which comprises a non-sliplayer 40. Vertical line A-A′ cuts through an embedded hard degradablepolymeric particle 52, forming a partial embedded hard degradablepolymeric particle 254B. The luxury vinyl tile 430 has a verticalsubstantially smooth cut edge 332. As a result, surface coveringmaterial 430 includes an embedded particle layer 250B which comprisesone or more transparent embedded hard degradable polymeric particles2526 and a partial transparent hard embedded degradable polymericparticle 254B. The embedded particle layer 250B is provided in wearlayer 36. In an alternative embodiment, cut line A-A′ may be at an angle(e.g. an acute or an oblique angle) such that smooth cut edge 332 is abevelled edge.

The sixth embodiment of a floor-covering material according to theinvention is indicated generally at 530 on FIG. 6 . Like features of thesixth embodiment 530 to the fourth embodiment of the floor-coveringmaterial 330 are identified by like reference numerals. Floor-coveringmaterial 530 is in the form of a tile or a cut piece of floor-coveringmaterial and has been cut from the floor-covering material 330 accordingto the fourth embodiment of the invention along the vertical line B-B′indicated on FIG. 4 . Floor-covering material 430 comprises the layersof a floor-covering material 130 according to the second embodimentwhich are a lower layer 232 of synthetic material, a support layer 33 inthe form of a scrim complex arranged on an upper surface of the lowerlayer 232, a layer of synthetic material in the form of pigmentedtopcoat layer 236 on an upper surface of the support layer 33, apolyacrylate protective coating layer 38 incorporating the non-sliplayer 40 on an upper surface of the pigmented topcoat layer 236. Thefloor-covering material 430 incorporates an embedded pigmented particlelayer 35013 comprising one or more pigmented embedded hard degradablepolymeric particles 3526 and pigmented embedded soft degradablepolymeric particles 352C in pigmented topcoat layer 236. Vertical lineB-B′ cuts through an embedded pigmented hard degradable polymericparticle 352B, forming a partial embedded hard pigmented degradablepolymeric particle 3546 and the luxury vinyl tile 530 has a verticalsmooth cut edge 432. As a result, the particle layer 350 comprises aplurality of one or more pigmented embedded hard degradable polymericparticles 352B, one or more pigmented embedded soft degradable polymericparticles 352C and a partial degradable polymeric particle 354B. Theembedded particle layer 35013 is provided in topcoat layer 236. In analternative embodiment, cut line B-B′ may be at an angle such thatsmooth cut edge 432 is a bevelled edge.

In an alternative embodiment, the pigmented printing layer 37 offloor-covering material 30,130,230,430 may be a foamed pigment printinglayer 37 such that the pigment printing layer 37 is formed from aplasticised polymer composition which comprises a foaming or expandingadditive and the printed decorative layer 34 may be printed with one ormore inks which selectively inhibit the foaming or expanding additivesuch that the floor-covering material 30,130,230,430 may be chemicallyembossed.

A first comparative embodiment of a floor-covering material is indicatedgenerally at C30 on FIG. 6 . Like features of the first comparativeembodiment to the second embodiment of the floor-covering material areidentified by like reference numerals. Comparative floor-coveringmaterial C30 is in the form of a luxury vinyl tile and has been shown asif cut from a comparative floor-covering material (not shown) along avertical line (not shown). Comparative floor-covering material C30comprises the layers of a floor-covering material 330 according to thefourth embodiment which are the lower layer 32 in the form of a foamedPVC layer, a support layer 33, an impregnation layer 35, a pigmentedprinting layer 37, a printed decorative layer 34, a wear layer 36, and aprotective coating layer 38 which comprises a non-slip layer 40.Polymeric particle layer 250 has been replaced by a inorganic particlelayer 60 comprising inorganic particles 62. Cutting the tile C30 downthe said vertical line dislodged a inorganic particle 62, forming apartial void 66 such that the comparative luxury vinyl tile C30 has arough cut edge C32. As a result, the inorganic particle layer 60comprises a plurality of a inorganic particles 62 and a partial void 66.The inorganic particle layer 60 is provided in wear layer 36. In analternative embodiment, inorganic particle layer 60 may have one or moreprotruding particles 68 (as illustrated in FIG. 7 for the secondcomparative embodiment of a floor-covering material D30) at rough cutedge C32.

A second comparative embodiment of a floor-covering material isindicated generally at D30 on FIG. 7 . Like features of the firstcomparative embodiment to the fifth embodiment of the floor-coveringmaterial 430 are identified by like reference numerals. Comparativefloor-covering material D30 is in the form of a tile or a cut piece offloor-covering material and has been shown as if cut from a comparativefloor-covering material (not shown) along a vertical line (not shown).Comparative floor-covering material D30 comprises the layers of afloor-covering material 430 according to the fifth embodiment which area lower layer 232 of synthetic material, a support layer 33 in the formof a scrim complex arranged on an upper surface of the lower layer 232,a pigmented topcoat layer 236 on an upper surface of the support layer33, a polyacrylate protective coating layer 38 incorporating thenon-slip layer 40 on an upper surface of the pigmented topcoat layer236. Polymeric particle layer 350 has been replaced by an inorganicparticle layer 60. Cutting the tile D30 down the said vertical linedislodged an inorganic particle 62, forming a partial void 66 such thatthe comparative tile D30 has a rough cut edge D32. As a result, theinorganic particle layer 60 comprises a plurality of inorganic particles62 and a partial void 66. The inorganic particle layer 60 is provided inwear layer 36.

The floor-covering material 30,130,230,330,430 may optionally beembossed. The floor-covering material 30,130,230 may be provided as aroll of floor-covering material or may optionally be cut up into tiles.

The invention will now be illustrated with reference to the followingExamples which are not intended to limit the scope of the claimedinvention.

EXAMPLE 1

The method of the invention was performed to prepare a floor-coveringmaterial 30,130,230 according to the invention having a printeddecorative layer 34 by carrying out the following steps:

-   -   a. coating a non-woven glass fibre with an impregnation layer of        plastics material and gelling (the coating) with temperatures        higher than 120° C., particularly on a heated drum;    -   b. Applying a printing layer formed from a pigmented plasticised        PVC composition which may optionally comprise one or more        foaming or expanding additives;    -   c. gelling the pigmented printing layer on a heated drum;    -   d. Printing onto the surface of the pigmented printing layer        using gravure printing one or more pigmented inks to form a        decorative layer, where the pigmented ink could be transparent        or opaque and wherein one or more of the pigmented inks include        an inhibitor for the foaming or expanding additive in the        printing layer for preparing a chemically embossed        floor-covering material;    -   e. Drying the printed ink with heat;    -   f. Inverting the product;    -   g. Applying a backing layer comprising either a foam-forming        plastics material comprising a plasticised PVC composition, or a        compact-forming plastics material comprising a plasticised PVC        composition to form an alternative embodiment to the        floor-covering material 30,130,230 where the lower layer is a        compact lower layer;    -   h. Optionally applying a fleece layer to the backing layer (to        form a floor-covering material 230 according to a third        embodiment of the invention);    -   i. Gelling the backing layer on a heated drum;    -   j. Inverting the product;    -   k. Applying a wear layer comprising a clear plastics material        having a plasticised PVC composition;    -   l. Scattering the polymeric material into the surface of the        plasticised PVC composition    -   m. Gelling the wear layer either on a heated drum or in an oven        to form a floor-covering material according to the first        embodiment of the invention;    -   n. Embossing the wear layer physically, optionally using        sufficient temperature and pressure to ensure that at least some        of the degradable polymeric particles are entirely incorporated        into the wear layer and do not protrude;    -   o. Cooling the embossed floor-covering material according to the        first embodiment of the invention;    -   p. Applying a protective coating layer (optionally containing        slip resistant particles to form a surface covering 130        according to the second embodiment of the invention) and curing        it to form a floor-covering material according to the second        embodiment of the invention;    -   q. Winding the product into a roll of the required length; and        optionally    -   r. Cutting the product into tiles to form a floor-covering        material 430 according to the fifth embodiment of the invention        or a variant thereof.

EXAMPLE 2

The method of the invention was performed to prepare a floor-coveringmaterial 330 according to the fourth embodiment of the invention bycarrying out the following steps:

-   -   a. Coating a scrim complex with a lower layer comprising an        unfoamed PVC plastisol to form a compact lower layer;    -   b. Gelling the plastisol in an oven;    -   c. Inverting the product;    -   d. Applying a pigmented topcoat layer having a plasticised PVC        composition;    -   e. Scattering a layer of the degradable polymeric particles into        the surface of the plasticised PVC composition    -   f. Gelling the pigmented topcoat layer in an oven to form an        alternative embodiment of the floor-covering material according        to the fourth embodiment of the invention which lacks a        protective coating layer;    -   g. Embossing the pigmented topcoat layer, optionally using        sufficient temperature and pressure to ensure that at least some        of the degradable polymeric particles are entirely incorporated        into the pigmented topcoat layer and do not protrude;    -   h. Cooling the embossed floor-covering material;    -   i. Applying a polyacrylate protective coating layer containing        slip resistant particles and curing it to form a floor-covering        material according to the fourth embodiment of the invention;    -   j. Winding the product into a roll of the required length; and        optionally    -   k. Cutting the product into tiles to form a floor-covering        material 530 according to the sixth embodiment of the invention.        This may include cuts which are perpendicular to the surface of        the flooring (e.g. to cut the product into the shape of the        required tile) or cuts at an angle to the surface of the        flooring (e.g. to provide a bevelled edge to a tile).

1. A synthetic slip-resistant floor-covering material comprising a layerof synthetic material which contains one or more degradable polymericparticles wherein the one or more degradable polymeric particlescomprise: (a) one or more hard degradable polymeric particles which havea hardness which is greater than the hardness of the layer of syntheticmaterial; and optionally (b) one or more soft degradable polymericparticles which have a hardness which is the same as or less than thehardness of the layer of synthetic material; and wherein the one or morehard degradable polymeric particles comprise one or more exposed harddegradable polymeric particles which are exposed at an upper surface ofthe synthetic floor-covering material to provide slip-resistance.
 2. Thefloor-covering material as defined in claim 1 which has a layer of oneor more hard degradable polymeric particles which are partially embeddedin an upper surface of the floor-covering material.
 3. Thefloor-covering material as defined in claim 1 wherein the one or morehard degradable polymeric particles comprise one or more degradablepolymeric particles which are entirely embedded in a layer of syntheticmaterial.
 4. The floor-covering material as defined in claim 1 whereinthe one or more degradable polymeric particles are transparent orpartially opaque.
 5. The floor-covering material as defined in claim 1wherein the one or more hard degradable polymeric particles are formedfrom a polyester.
 6. The floor-covering material as defined in claim 1wherein one or more soft degradable polymeric particles are entirelyembedded in a layer of synthetic material.
 7. The floor-coveringmaterial as defined in claim 1 wherein one or more soft degradablepolymeric particles comprise one or more decorative soft degradablepolymeric particles.
 8. The floor-covering material as defined in claim1 wherein one or more soft degradable polymeric particles are formedfrom a polyhydroxyalkanoate and/or an acrylic copolymer.
 9. Thefloor-covering material as defined in claim 1 wherein the one or moredegradable polymeric particles may have a principal dimension of from15% to 90% of the thickness of the layer of synthetic material.
 10. Thefloor-covering material as defined in claim 1 wherein the layer ofsynthetic material and the one or more degradable polymeric particlesare pigmented.
 11. The floor-covering material as defined in claim 1wherein the one or more degradable polymeric particles is formed from apolymer which has a melting point greater than 120° C.
 12. Thefloor-covering material as defined in claim 1 which comprises aprotective coating layer on an upper surface of the layer of syntheticmaterial to form an upper layer of the floor-covering material.
 13. Thefloor-covering material as defined in claim 1 which additionallyincludes one or more of the following layers: a foamed layer, a supportlayer, a decorative layer, a topcoat layer, and/or an externalprotective coating layer.
 14. The floor-covering material as defined inclaim 1 which is in the form of a luxury vinyl tile comprising adecorative layer and wherein the layer of synthetic material is providedon an upper surface of the decorative layer and wherein the layer ofsynthetic material is substantially transparent.
 15. The floor-coveringmaterial as defined in claim 1 wherein the layer of synthetic materialincludes one or more partial degradable polymeric particles.
 16. Thefloor-covering material as defined in claim 1 wherein the layer ofsynthetic material is pigmented or is substantially transparent.
 17. Thefloor-covering material as defined in claim 1 wherein the layer ofsynthetic material is a wear layer.
 18. The floor-covering material asdefined in claim 1 wherein the one or more hard degradable polymericparticles and/or the one or more soft degradable polymeric particles arebiodegradable, oxidatively degradable, UV-degradable, and/or thermallydegradable.
 19. A method of preparing a synthetic floor-covering whichmethod comprises the steps of: Providing a layer of synthetic material;Applying the one or more degradable polymeric particles to the layer ofsynthetic material; and Applying pressure to the layer of syntheticmaterial to ensure that the one or more degradable polymeric particlesare incorporated into the layer of synthetic material.
 20. The method ofpreparing a synthetic floor-covering as defined in claim 19 which methodcomprises the step of: applying a protective coating layer wherein thisstep is carried out after the step of applying pressure to the layer ofsynthetic material.
 21. The floor-covering material as defined in claim10 wherein the pigment of the one or more degradable polymeric particlesis the same as the pigment for the layer of synthetic material.
 22. Thefloor-covering material as defined in claim 14 which comprises a lowerfoamed layer.
 23. The floor-covering material as defined in claim 14which has a substantially smooth cut edge.